Wearable headlight devices and related methods

ABSTRACT

Wearable headlight devices and related methods are provided and can include a luminaire that can include a housing having a luminaire vent therein for receiving cooling air and a light source contained within the housing. An air moving device can be located outside of the luminaire for facilitating cooling air intake through the luminaire vent. An exhaust tube can be connected to the luminaire and the air moving device to facilitate air flow of the cooling air between the luminaire and the air moving device.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S. patentapplication Ser. No. 14/553,512, filed Nov. 25, 2014, now U.S. Pat. No.9,400,101, which is a continuation of and claims priority to U.S. patentapplication Ser. No. 13/069,288, filed Mar. 22, 2011, now U.S. Pat. No.8,899,774, which claims the benefit of and priority to U.S. ProvisionalPatent Application Ser. No. 61/414,739, filed Nov. 17, 2010, thedisclosures of which are incorporated herein by reference in theirentirety.

TECHNICAL FIELD

The subject matter disclosed herein relates generally to headlights tobe worn on a user's head to provide supplemental light. Morespecifically, the subject matter disclosed herein relates to wearableheadlight devices and methods utilizing a light source such as a lightemitting diode (“LED”) devices.

BACKGROUND

Existing surgical headlights require a significant amount of light,approximately 400 lumens minimum for example, to provide sufficientillumination for a surgeon during a typical procedure. Surgicalheadlights must also be lightweight and typically weigh less than 400grams for example, so that neck and head fatigue is minimized. Tosatisfy both conditions, the following architecture is utilized by mostmanufacturers: a remote Xenon light source is optically coupled to afiber optic cable that transmits light energy to the luminaire which ismounted on a head wearable portion. The luminaire focuses the light andproduces a spot of bright light typically 120 mm in diameter at 400 mmaway from the luminaire. There are several disadvantages of thisarchitecture. First, the surgeon is tethered to a large light source,which constrains his or her movement. Second, the light source takes upvaluable room in the operating room. Third, the light source typicallyconsumes about 380 W of power. Fourth, the Xenon lamps are expensive andmust be replaced periodically. Typical life is about 650 hours. Fifth,fiber optic cables are expensive, fragile and must be replacedperiodically. Sixth, additional optical components and assemblies may berequired for filtering out UV and IR.

LEDs are semiconductor devices that emit light by application ofelectrical power (watts). White light LED technology has advanced to thepoint where one LED can produce as much as 1200 lumens. This makes it afeasible light source for a surgical headlight luminaire. An LEDsurgical headlight can achieve light output and weight requirements. Aproblem however with LEDs is that they generate heat that must beaddressed, and one of the major challenges LEDs pose in manyapplications is dissipating and/or removing the heat generated by anLED. Excess heat must be removed so that the semiconductor junctiontemperature does not exceed recommended maximum temperature. Inaddition, as the junction temperature of the LED rises, the efficiencyalso drops. LED light output is limited by its maximum heat junctiontemperature, so to increase light output without damaging the LED orreducing its operating efficiency, heat must be transferred quickly andefficiently.

There remains a need for improved headlight devices and methods thatsatisfy weight and light output expectations.

SUMMARY

It is an object of the present disclosure to provide novel headlightdevices and methods, such as for surgical procedures for example, wherethe devices are efficiently cooled to maintain light output, efficacy(efficiency), reliability and life. It is another object to providecompact LED luminaire optics with enhanced light output.

A few objects of the presently disclosed subject matter having beenstated hereinabove, and which are achieved in whole or in part by thepresently disclosed subject matter, other objects will become evident asthe description proceeds when taken in connection with the accompanyingdrawings as best described hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present subject matter includingthe best mode thereof to one of ordinary skill in the art is set forthmore particularly in the remainder of the specification, includingreference to the accompanying figures, in which:

FIG. 1 illustrates a perspective view of an embodiment of a headlightdevice in accordance according to an embodiment of the subject matterdisclosed herein;

FIG. 2 illustrates an exploded view of the embodiment of the headlightdevice according to FIG. 1;

FIG. 3 illustrates a perspective view of an embodiment of an LEDluminaire in accordance with the subject matter disclosed herein;

FIGS. 4A and 4B illustrate additional LED luminaire embodiments inaccordance with the subject matter disclosed herein;

FIGS. 5A and 5B illustrate cross-sectional views along the length of theembodiments of the LED luminaire of FIGS. 4A and 4B to illustrate theinternal configurations;

FIG. 6 is a schematic cross-sectional view of an internal configurationof the luminaire embodiment of FIG. 4B;

FIG. 7 illustrates an exploded view of an embodiment of a light-emittingdiode package in accordance with the subject matter disclosed herein;

FIG. 8A illustrates a perspective view of an embodiment of a thermalconductive board that can be laminated to an embodiment of a printedcircuit board (“PCB”) used in the embodiment of the light-emitting diodepackage according to FIG. 7;

FIG. 8B illustrates a perspective view of an embodiment of the PCB usedin the embodiment of the light-emitting diode package according to FIG.7; and

FIG. 9 illustrates a perspective view of an embodiment of an opticalconstruction or configuration that can be used in an embodiment of aluminaire in accordance with the subject matter disclosed herein; and

FIG. 10 illustrates a schematic diagram of an embodiment of componentsthat can be used to control the temperature of a light source inaccordance with the subject matter disclosed herein.

DETAILED DESCRIPTION

Reference will now be made in detail to the description of the presentsubject matter, one or more examples of which are shown in the figures.Each example is provided to explain the subject matter and not as alimitation. In fact, features illustrated or described as part of oneembodiment may be used in another embodiment to yield still a furtherembodiment. It is intended that the present subject matter cover suchmodifications and variations.

As noted above, improved headlights, such as wearable surgicalheadlights, and methods are disclosed herein that can utilize lightemitting devices, such as for example light emitting diodes (LEDs). Theuse of LEDs in a wearable headlight device as disclosed herein hasadvantages over conventional Xenon based wearable headlights. Forexample and as disclosed in further detail herein, an LED headlight canbe powered by a portable battery pack worn by the user, thus allowingfreedom of movement. Also, an LED headlight does not require a remotelight source since the LED can be integrated into the luminaire.Additionally, an LED headlight can consume for example only about 5% (20W) of power utilized by a Xenon light source. LED life canadvantageously be for example up to 50,000 hours depending upon drivecurrent and operating temperature. Finally, LED headlights do notrequire fiber optic cables, and white light LEDs advantageously do notgenerate significant amounts of UV or IR.

FIGS. 1 and 2 show a wearable headlight device generally designated 10in accordance with some embodiments of the subject matter disclosedherein. Headlight device generally designated 10 can comprise aluminaire 20. Headlight device 10 can optionally comprise a headwearable portion generally designated 12 with luminaire 20 attached tohead wearable portion 12 as shown in FIGS. 1 and 2. Headlight device 10is thus a medical device that can for example and without limitation beworn on a surgeon's head to provide supplemental light for surgical andmedical procedures, whenever supplemental illumination, especiallyshadow-free coaxial illumination, is desired or required to facilitate asurgical or medical procedure. The intended user for headlight device 10can be, for example, physicians, surgeons and other trained, qualifiedmedical professionals providing medical or surgical assistance. Intendedpatients can be any individuals undergoing surgical or medicalprocedures where additional illumination is deemed necessary by apractitioner performing a procedure.

Head wearable portion 12 can be plastic and can be configured to attachto and securely position one or more devices and can be adapted to beworn on a user's head. It is commonly configured and referred to as aheadband. Head wearable portion 12 can comprise overhead straps 12A and12B that can form an arch that can rest upon a top portion (or crown) ofthe head of the user. Head wearable portion 12 can be adjustable to fitthe head of the user. For example, adjuster 12C, such as a ratchet knob,can be used to adjust the position of overhead straps 12A and 12Brelative to one another. For instance, if adjuster 12C is rotated in afirst direction, then overhead straps 12A and 12B can be pulled closertogether to accommodate a smaller crown of the head. If the adjuster 12Cis rotated in a second direction opposite the first direction, thenoverhead straps 12A and 12B can be pushed away from each other toaccommodate a larger crown of the head.

Head wearable portion 12 can comprise a rear headband portion 120 and afront headband portion 12E. As shown in FIGS. 1 and 2, rear headbandportion 120 can comprise two straps 12D₁ and 12D₂ and rear headbandportion 120 can also be adjustable. Rear headband portion 120 cancomprise an adjuster 12F that can be used to adjust the position ofstraps 12D₁ and 12D₂ relative to one another to adjust to the head sizeof the user. For instance, if adjuster 12F is rotated in a firstdirection, then straps 12D₁ and 12D₂ can be pulled closer together toaccommodate a smaller head. If the adjuster 12F is rotated in a seconddirection opposite the first direction, then straps 12D₁ and 12D₂ can bepushed away from each other to accommodate a larger head. Thus, with theadjustability for both the crown and the head size of the user, headwearable portion 12 can be comfortably conformed to the user's head.Head wearable portion 12 can utilize replaceable/disposable foam padsets for front headband portion 12E, rear headband portion 120, andoverhead straps 12A and 12B for respectively padding the forehead, backand crown of the user. Headband pads can attach to the headband via ahook and loop system.

A luminaire generally designated 20 can be located along front headbandportion 12E of head wearable portion 12. For example, a connectorgenerally designated 22 can be used to hold luminaire 20 to frontheadband portion 12E so that luminaire 20 can be positioned between theeyes of the head of the user. Connector 22 can include a connector base22A that can be rigidly attached to front headband portion 12E byfasteners 22B shown for example in FIG. 2. A connector link 22C can berotatably connected to connector base 22A on one end and rotatablyconnected to a connector receiver 22D on luminaire 20. Since connectorreceiver 22D can be moved relative to the connector base 22A through therotatable connections with connection link 22C, luminaire 20 can bemoved relative to head wearable portion 12 and when in use, relative tothe head of the user. In some embodiments, one or more links can beused. For example, connector link 22C can be rotatably connected toconnector base 22A on one end and rotatably connected to a second link(not shown) that is rotatably connected to connector receiver 22D onluminaire 20. In such embodiments, increased rotation of luminaire 20may be achievable. The position and orientation of luminaire 20 can thusbe adjustable with force by the user but remain fixed during intendeduse.

Luminaire 20 can also comprise a luminaire housing 24 to contain thecomponents of luminaire 20. Luminaire housing 24 can comprise one ormore venting tubes such as venting tubes 26 at a top end that can bedistal from an outer lens 42 (FIG. 3) of luminaire 20. Venting tubes 26can be used to vent or express hot air out of luminaire housing 24. Forexample, head wearable portion 12 as shown in FIG. 2 particularly canalso comprise a controller 13 that can comprise a controller housing 14that can hold a controller board 14A. Controller housing 14 can alsohouse an air moving device 30, such as a fan, that can create anairflow. Thus, an active cooling system for headlight device 10 caninclude one or more exhaust tubes 18, which can be or can include someflexible portion or portions, and controller housing 14 with air movingdevice 30, such as an exhaust fan. Controller 13 can also be located inany other suitable location and even not attached to head wearableportion 12. In some embodiments, a single exhaust tube 18 can beprovided to facilitate the airflow through and away from luminaire 20.For example, a single exhaust tube 18 can run along a side or over a topportion of head wearable portion 12.

While headlight device 10 is described with a head wearable portion thatis separate from exhaust tubes 18, in some embodiments, the exhausttubes, such as exhaust tubes 18, can comprise the head wearable portion.In such embodiments, exhaust tubes 18 can be rigid enough to holdluminaire 20 and control housing 14 on a head of a user. Luminaire 20can be connected to exhaust tubes 18 to permit airflow to pass fromluminaire 20 to exhaust tubes 18, while also allowing luminaire 20 to beadjustable relative to exhaust tubes 18.

Controller housing 14 can extend outward from head wearable portion 12above rear headband portion 12D and can be constructed, for example, ofRadel® high temperature, UL94 VO engineering resin. Controller housing14 can be the just the back portion in which controller board 14Aresides or both the front and back portions shown in FIG. 2. Controllerhousing 14 can include air flow tubes 14B that can be rigid and can bein fluid flow communication with air moving device 30. Control housing14 can be secured to head wearable portion 12 in a variety of manners.In the embodiment shown in FIGS. 1 and 2 for example, connectors 16 thatcan include fasteners 16A can be used to secure controller housing 14 tooverhead straps 12A and 12B. As shown, connectors 16 can be locatedrespectively above a portion of air flow tubes 14B. The one or moreventing tubes 26 can be connected to air flow tubes 14B by exhaust tubes18. Exhaust tubes 18 can be flexible to permit movement of luminaire 20relative to head wearable portion 12. Thus, through an airflow createdby air moving device 30, hot air can be pulled from luminaire housing 24through the one or more venting tubes 26 and exhaust tubes 18 to airflow tubes 14B. From air flow tubes 14B, the air is pulled out andthrough air moving device 30.

Controller housing 14 can also include a power connector 14C that can beconnected to a power supply to supply power to control board 14A and airmoving device 30 in controller housing 14. Further, connector 14C canalso supply power to luminaire 20. Both the cooling system and the powersupply system are described further below.

As shown in FIG. 3, luminaire 20 can comprise outer lens 42. As shown inFIGS. 1, 2, 3, 4A and 4B, luminaire 20 can also comprise an iriscontroller 44 which can be rotatable relative to luminaire housing 24for controlling the degree of dilation or constriction of an iris 60(see FIGS. 5A, 5B, 6, and 9) within luminaire 20. Iris controller 44 cancomprise an exterior wheel to control the opening of iris 60. Iriscontroller 44 can have an instrument feel provided by oring or wavespring, for example, to enhance the gripping of iris controller 44.Luminaire housing 24 can also comprise an angled back 24A that canreside below the portion of the housing in which LED light source 50described further below resides. A mirror (FIG. 9) can reside on aninterior portion of angled back portion 24A to angle the light generatedby LED light source 50. Luminaire housing 24 can also comprise an outerlens housing 24B that extends outward from luminaire housing 24 andangled back portion 24A. Outer lens housing 24B can have outer lens 42reside therein.

Luminaire housing 24 can comprise a suspension ring 31 that can includea luminaire skirt 31A. Connector receiver 22D can extend from suspensionring 31 to provide connection to head wearable portion 12 as describedabove. Luminaire housing 24 can also comprise luminaire vents. Luminairevents can be constructed in many ways as apparent to a person skilled inthe art. For example, luminaire housing 24 can include a vent ring 34A(see FIG. 4A) or 34B (see FIG. 4B). In FIG. 4A, vent ring 34A can haveluminaire vents 36A that are visible. Alternatively, as illustrated inFIG. 4B, vent ring 34B can have luminaire vents generally designated 36Bthat can be constructed so luminaire skirt 31A covers the luminairevents 36B so that an individual viewing the front of the luminairecannot see vents 36B. Above the suspension ring 31, luminaire housing 24can also comprise a vent tube portion that can include one or moreventing tubes 26 as described previously.

As shown in FIGS. 5A, 5B and 6, luminaire 20 can comprise a light source50, a heat sinking device, or heat sink 52, and optics 40 (see FIG. 9including iris control 44 in FIGS. 5A, 5B and 6) within the luminairehousing. Light source 50 can comprise one or more different or identicallight sources, such as light bulbs, light-emitting diodes (LEDs),lasers, and the like. In the embodiments shown for illustrationpurposes, light source 50 can comprise an LED light source, which cancomprise one or more LEDs. Heat sink 52 can reside in a heat sinkingchamber in suspension ring 31 and can be in thermal communication withLED light source 50. For example, heat sink 52 can be in direct contactwith LED light source 50 or a thermal conductive material may residebetween LED light source 50 and heat sink 52.

As discussed above, the cooling system for luminaire 20 can compriseluminaire vents 36A, 36B or intake vents located within luminairehousing 24. Luminaire vents 36A, 36B can receive cooling air that canpass over heat sink 52 and can be discharged from luminaire housing 24through the one or more venting tubes 26 to a location outside of andaway from luminaire 20 and heat sink 52. As described above, air can bepulled and flow through luminaire vents 36A. 36B, over the heat sink todissipate and remove heat through venting tubes 26 and exhaust tubes 18.From there, the air that has now been heated by the heat sink can bepulled and flow through air flow tubes 14B and through air moving device30. Air moving device 30 can generate the air flow that pulls airthrough the luminaire vents 36A, 36B and through air moving device 30,expelling the heated air away from the head of the user. In someembodiments of the present subject matter, LED cooling can achieved byan air moving device 30 that comprises, for example, a Sunon® 1 Wattfan. Controller board 14A can provide a thermal cut out that can shutdown LED light source 50 if it overheats as described further below. Thebrightness of LED light source 50 can be controlled by controller board14A varying the current supplied to LED light source 50.

As described previously, controller housing 14 can also have controllerboard 14A residing therein which can control and/or adjust the operationof air moving device 30 and light source 50. For example, controllerhousing 14 can house a thermostat, a switch for a power supply, andswitch for air moving device 30. In such an embodiment, where thethermostat is in the controller housing 14, a temperature sensor can bedisposed in proximity to light source 50. In one aspect, a thermostat Tcan be in proximity of the light source 50 as shown schematically inFIG. 10. Wiring 53 can pass from controller board 14A and connector 14Cthrough air flow tubes 14B, exhaust tubes 18, and venting tubes 26 tolight source 50 to supply power to LED light source 50 and to providecommunication to control and adjust the light output from light source50.

As shown in FIGS. 7, 8A and 8B, LED light source 50 can comprise an LEDlens 50A that can resides and be disposed over a mounting pad that caninclude electrical traces and the diodes (not shown) that will emitlight when powered. The mounting pad and electrical traces can reside ona substrate that can form an LED base, or slug, 50B. A printed circuitboard (PCB) 54 can be electrically connected to LED 50. PCB 54 can havean opening 54A therethrough. A thermal conductive board, or heat sinkpad, 56 can be laminated to PCB 54. Thermal conductive board 56 cancomprise a protrusion 56A that can extend up through opening 54A in PCB54 and can be soldered directly to LED base 50B. In some embodiments,thermal conductive board 56 and protrusion 56A can be a conductive metalsuch as copper for example. Thermal conductive board 56 can be securedto heat sink 52 in a manner that will facilitate thermal transfer fromthermal conductive board 56 to heat sink 52.

A method of heat transfer from LED light source 50 that can be used inheadlight device 10 to efficiently transfer heat energy from LED 50 canbe conduction from LED base 50B. Light output from LED light source 50can be limited by its maximum heat junction temperature. To increaselight output without damaging LED light source 50 or reducing itsoperating efficiency, heat can be transferred quickly and efficiently byreducing the thermal resistance at LED base 50B so that the heattransfer rate can be increased. Copper protrusion 56A can extend upthrough opening 54A in PCB 54 and can be soldered directly to LED base50B, thereby greatly reducing thermal resistance. By soldering LED base50B directly to copper protrusion 56A that extends from copper thermalconductive board 56, the thermal resistance can be greatly reduced. Insome embodiments, LED light source 50 and heat sink 52 located inside ofthe luminaire can be in direct thermal contact with each other. Toprovide more surface area to remove heat from heat sink 52, heat sink 52can comprise a plurality of projections 52A that extend from a backsurface of heat sink 52 away from LED light source 50.

PCB 54 is shown in FIGS. 7, 8A and 8B as two pieces for clarity. Thermalconductive board 56 can be a copper piece and can be laminated to board54, which can be a polyamide or FR4 board using epoxy laminating processcommon in the PCB industry. Protrusion 56A can extend up through opening54A in PCB 54 and soldered directly to LED base 50B of LED light source50. Direct soldering of LED solder pad to copper core board may yield alow thermal resistance, and thus a low junction temperature. Thisthermal cooling design enables LED light source 50 to generate morelumens in response to receiving more cooling, as compared to an LEDreceiving cooling from a heat sink that is not in direct thermal contactwith the LED.

Optics 40, shown in FIG. 9, can provide an arrangement of opticalcomponents within the luminaire designed to efficiently capture lightfrom LED light source 50 and to project the light with high qualitycharacteristics along an axis that is at least proximate to beingparallel to the line of sight of the wearer. These high qualitycharacteristics can include projection of a pre-determined andadjustable light spot size at a particular distance from the wearer thatcan be substantially free of cosmetic defects (artifacts) and that canbe projected in a direction and with a well-defined edge to limitshadowing and collateral glare.

FIGS. 5A, 5B, 6 and 9 illustrate LED luminaire optics 40 and itscomponents in accordance with an embodiment of the subject matterdisclosed herein. Optics 40 can be based on the principle of Koehlerillumination and can comprise one or more condensing lens 43, 45 and oneor more objective lens 42, 46 with iris 60 and folding mirror 48 placedin between. In the embodiment shown in FIGS. 5A, 5B, 6 and 9, a firstcondensing lens 43 is positioned proximate to lens 50A of LED lightsource 50 to maintain a compact and cost effective format. Firstcondensing lens 43 can be constructed from high index glass. A secondcondensing lens 45 can be placed below and proximate to first condensinglens 43 to provide a doublet of elements. Second condensing lens 45 canalso comprise high index glass, for example, Schott LaSFN 31 or opticalequivalent. To maximize collection efficiency, the first condensing lens43 can be placed in close proximity to the LED dome or lens 50A and canbe shaped as a meniscus lens. The optical design can feature a highcurvature meniscus lens located a distance, for example, of about 0.25mm, from the LED dome for maximum light collection. The function ofcondensing lenses 43, 45 can be to efficiently collect light(represented by the lines and arrows in FIG. 9) from LED light source 50and back-illuminate an iris 60 with a beam that has a uniform lightdistribution and can be properly sized to an opening in iris 60.

To maintain a compact cost effective optics format, objective lenses cancomprise first objective lens 46 and second (or outer) objective lens 42to provide a split doublet. The light can pass through iris 60 towardfirst objective lens 46 which directs or focuses the light towardfolding mirror 48. First objective lens can comprise high index glass aswell. The light can reflect off of folding mirror 48 at an angle towardouter objective lens 42 which can provide a light beam focused in themanner desired by the user. Second, or outer, objective lens 42 can alsocomprise high index glass. The function of first objective lens 46 andsecond (or outer) objective lens 42 can be to project the image of theiris opening at the prescribed spot diameter, with a high degree oflight uniformity, no objectionable artifacts inside or outside the spot,and with good edge definition across the entire range of workingdistances and iris openings.

As shown in FIG. 9, condensing lens 43 captures and focuses the lightfrom LED light source 50 toward larger condensing lens 45 which in turnfocuses the light through iris 60. Particular attention can be paid tothe selection of glasses and lens curvatures that yield a minimal amountof lateral chromatic aberration at the edge of the spot. The luminairecan utilize a classic Koehler optical design (projector optics) with anoptical efficiency of, for example, about 71%.

The compact LED luminaire optics 40 shown in FIG. 9 particularly can beoptimized with respect to one or more of the following factors: (1)large LED die combined with wide beam angle; (2) high collectionefficiency in a compact and lightweight luminaire system; (3) simplicityof the optics train (minimal number of optical components including anadjustable iris diaphragm and a folding mirror); (4) high spot quality(uniformity and light output) at the prescribed working distance, forexample, about 16 inches and for the full range of prescribed workingdistances, for example, about 10 inches to about 25 inches; and (5) aprojected spot that does not have a “memory” of the square shape of LEDlight source 50 or its surface structure.

Headlight device 10 can be configured for either battery powered ordirect powered use. For example, headlight device 10 can be configuredfor direct power and battery power, respectively. Such a headlightdevice can be designed to provide illumination to aid visualizationduring minor surgical, diagnostic, or therapeutic procedures.

Headlight device 10 can be a self-contained headlight system that can beoperated using either battery or direct power supply. Using a batterypack 76 (see FIG. 2) can give a surgeon complete portability allowingunrestricted movement in and around the operating suite. Power can forexample be supplied by a medical grade 12 VDC, 3.0 A power supply. Thedirect power supply option 72 and 74 (see FIG. 2) can be used as aprimary power source for unlimited operating time, or as a back-up tothe battery system. A 15 VDC supply can power a linear power supplywhich can power LED light source 50 and air moving device 30.

When headlight device 10 is powered by rechargeable battery packs,controller board 14A can monitor the remaining battery power availableand can provide both audible and visual feedback to the user. Forexample and without limitation, a five segment LCD bar display on thebattery 76A can provide visual feedback to the user representing itsremaining charge status (0% to 100% in 20% increments). An audiblenotification can also be delivered to the user when a low batterycondition is detected. A three-tone cycle can sound at approximatelyfifteen minutes of charge remaining and can be repeated every threeminutes to notify the user that a new battery pack generally designated76 can be inserted or that a direct power supply can be attached toheadlight device 10.

Regarding power supply as mentioned previously, headlight device 10 cansupport AC line input. In some embodiments, as explained below, AC powersupply can be connected to a transformer that converts the power supplyto a DC power supply with a power connector 14C of headlight device 10being connected to the transformer. AC (wall power) operation option caninclude 3 distinct components: AC Power Cord 70 (see FIG. 2), MedicalGrade Switching Power Supply, and a replaceable low voltage power cord(not shown). AC Power can be delivered through a detachable countryspecific AC power cord 70 as shown in FIG. 2 connecting to a medicalgrade power supply using standard IEC connector 70A and a wall plug 70B.AC power cords can include USA/JAPAN, UK, EU, AUSTRALIA, styleconnectors. AC Power cord length can be any desirable length, forexample, about 8 feet+/− about 2 feet.

In some embodiments, connector 14C can be a DC output side of a powersupply and can have a 20 inch output cable with a connector for matingto headlight device 10. In this manner, a power supply can be connectedto headlight device 10 via a robust low voltage DC power cord 72. Thelength of power cord 72 can be any desirable length that will allow fordesired movement of the user, for example, about 20 feet. Low voltage DCpower cord 72 can terminate in connector end 72A and connector end 72B.Connector end 72B can be plugged into a connector on a transformer 74 oran umbilical cord (not shown) in transformer 74. The umbilical cord canalso be any desirable length. Connector end 72A can be electricallyconnected with connector 14C extending from controller housing 14. Lowvoltage DC power cord 72 can be capable of withstanding heavy abuseincluding frequent crushing forces caused by foot traffic and beingrolled over by wheeled medical devices to maintain electrical safety andconductivity. Low Voltage DC power cord 72 from the power supply toheadlight device 10 can be flexible enough to facilitate easy coilinginto a coil. Electrical connections from DC power cord 72 to headlightdevice 10 and connector 14C can be polarity non-specific. For example,controller 14A can determine polarity and compensate for eithercondition. DC electrical connections can be robust, securely lockinginto place and capable of 3000 cycles without producing electricalintermittence and reduction in insertion/retention forces to less thanabout 3 lbs. Controller 14A can have connector 14C connected thereto.Connector 14C can comprise have a low voltage DC cable terminating in aconnector for connection to a battery and holster or DC power supplycable.

In addition to or alternatively, headlight device 10 as shown in FIG. 2for example can include a battery system 76 that can comprise a battery76A, a connection cable 76B and a battery holster 76C, as well asbattery charger (not shown). Connection cable 76B can comprise a lowvoltage DC cable terminating in a connector 76B₁ for connection toconnector 14C. Cable 76B and connector 76B₁ can be the same as is usedon the switching power supply that switches AC current to DC current.The circuitry in battery holster 76C can provide an Audible Low BatteryWarning function. The targeted volume of the tone can be loud enough tobe heard in a busy operating room without being a distraction and canoperate at different hertz and for different amounts of time to helpindicate the level of battery power still available. Tones measured byan external microphone can approximate a sine wave. Battery 76A can havea charge state indicator 76D, such as a Liquid Crystal Display (LCD)Fuel Gauge. The battery charger (not shown) can be, for example, anINSPIRED ENERGY® single bay charger.

The color temperature for LED light source 50 can be set for theluminaire 20 based on the LED package used. Color temperaturevariability can be defined by standard binning by LED manufacturer. IRcontent can be a low percentage of total light output as measured fromthe luminaire. In one aspect and for example, UV content can also be alow percentage of total light output as measured from the luminaire. Thelight output of LED light source 50 can vary based on use and the LEDpackage used within Luminaire 20. For example, the light output of LEDlight source 50 can be in one aspect no less than about 350 lumens atfull power.

Iris 60 can have different numbers of leafs to provide adjustability fordilation or constriction of iris 60. Iris 60 can be, for example, a 10to 12 leaf iris that can provide a varying illumination spot diameter.The peak illuminance of the luminaire large spot can vary depending onthe user's preference and the LED package used on luminaire 20. The peakilluminance of the luminaire large spot can be bright enough to be usedin surgery. The spot can advantageously have no perceptible dark center.The design of luminaire 20 can minimize objectionable artifacts outsideor inside the illumination spot. Headlight spot quality and spotdefinition at a normal working distance (about 16 inches) can bepreserved through entire excursion of light source dimmer.

Headlight device 10 can include different settings for the level ofintensity of the light generated by light source 50. Depending on theneeds of a user, a wide range of settings for the level of lightintensity can be employed. For example, in one aspect headlight device10 can have a 4 position rotary switch (Off, Low, Med, and High) (notshown). Such a switch can be located on head wearable portion 12 and beeasily accessible to the right hand of the user as well as to anattendant. Luminaire 20 and headlight device 10 can automatically switchto the low setting for the level of light intensity in the event ofoverheating. If overheating continues in a low setting, headlight device10 can switch to a lower level default mode. Controller housing 14 canhouse a thermostatically controlled cooling fan that can be calibratedto maintain luminaire housing 24 that houses LED light source 50 at apredetermined temperature.

For example, as shown in FIG. 10, a temperature sensor T, such as athermostat for example, can be disposed at least proximate or in contactwith LED light source 50 to measure or determine the temperature of LEDlight source 50. Temperature sensor T can be electrically connected to,or at least in communication with, controller 13 and/or air movingdevice 30, such as a cooling fan. Alternatively, temperature sensor Tcan be electrically connected to, or at least in communication with,controller 13 and controller 13 can be electrically connected to, or atleast in communication with, air moving device 30. As the temperaturesensed by the temperature sensor T changes, controller 13 canautomatically control temperature of LED light source 50. For example,controller 13 can automatically control the speed of air moving device30, and thus the speed of airflow generated thereby. Further, controller13 can automatically control an intensity of the light from LED lightsource 50. These measures can facilitate control of the temperature ofLED light source 50, as described further below.

Headlight device 10 can in one aspect have a weight that can be lessthan or equal to about 400 grams with a target weight of about 330grams. Headlight device 10 minus the padding can be cleaned with commoncleaning and disinfection agents used in hospitals, e.g. 70% isopropylalcohol and CAVICIDE® wipes. Sterilization may not be required.Headlight device 10 can be designed to hold up to normal every dayhandling in the operating room environment, including for example beingdropped onto a tile floor from at least three feet. Gown clips can besupplied with each headlight device 10 to securely attach the electriccord to the surgical gown. All materials can be latex free.

LED headlight device 10 typical use can for example be four or moresurgeries per day with about an hour per surgery average for about fivedays per week. For such average use, headlight device 10 can providereliable service for at least three or more years. Headlight device 10can comprise one luminaire and optionally head wearable portion, twobattery packs, one battery holster, one battery charger with powersupply, one AC power supply, one DC cable, and accessories andreplacement parts.

Controller board 14A in headlight device 10 can include software tocontrol the intensity of light generated by LED light source 50 and airmoving device 30, such as a cooling fan, that draws air at a very lowflow rate through vents 36A, 36B on the side and back of luminaire 20thereby cooling LED light source 50 as necessary. The software canreside for example in controller board 14A. There can also be softwarelocated in battery pack 76 that can provide audible notification to theuser when the battery charge remaining is nearing its end.

The software can be a computer readable medium and can provide certainfunctionalities to controller board 14A of headlight device 10. Thesoftware can allow controller board 14A to be able to read thetemperature of LED light source 50 to within a small temperature range.The software can allow controller board 14A to detect an open circuitedLED temperature sensor as indicated by a temperature reading of below apredetermined temperature, for example, below freezing. The software canallow controller board 14A to be able to detect an over-temperaturecondition or a short circuited LED temperature sensor as indicated forexample by a temperature reading above a predetermined temperature. Thesoftware can allow controller board 14A, upon detection of an out ofrange temperature condition, for example, temperatures outside of arange between the temperature below the temperature indicating an opencircuited temperature sensor and the temperature indicating anover-temperature condition to be able to put LED light source 50 into afault condition that is below the lowest setting of the level of lightintensity for headlight device 10, set the fan to its lowest speed,and/or lock the system from use until the power is cycled.

The range operating temperatures of headlight device 10 can varydepending on the LED package used and the desired need for energyefficiency and light output. During a low normal operating LEDtemperature range, the software can allow controller board 14A toautomatically set air moving device 30 to a minimum speed. During amidrange normal operating LED temperature range, controller board 14Acan automatically vary the speed of air moving device 30 ranging from alow speed to a high speed and proportional to the temperature. Thus, atthis midrange temperature range, the speed of air moving device 30 canbe variable. During a high normal operating LED temperature range whereoverheating may become a concern, the software can allow controllerboard 14A to automatically set air moving device 30 to a high speed,such as a maximum speed for air moving device 30. During a hightemperature condition above the normal operating temperature range, thesoftware can allow controller board 14A to automatically set air movingdevice 30 to operate at its maximum level of performance and the lightsource 50 can be reduced to its lowest setting for the level of lightintensity. The software can allow controller board 14A to be able toautomatically switch to the lowest setting for the level of lightintensity in the event of overheating. If overheating continues in thislowest setting, controller board 14A can further reduce the level oflight intensity below the lowest setting of the LED through thesoftware.

The software can allow controller board 14A to be capable of controllingthe LED intensity as selected by the four-position rotary switch. Thesettings of control can, for example, be: Off, Low, Medium, and High.Software in either battery pack 76 or controller board 14A or any othersuitable location can provide an audible notification upon detection ofa low battery condition. These audible notifications can vary in numberand in timing. For example, a single audible notification can occur at apredetermined estimated time until the battery is expected to die withthe audible notification occurring until the battery dies. Anotherexample is provided below:

-   -   15 Minutes Remaining: 1 Audible Notification Cycle    -   12 Minutes Remaining: 1 Audible Notification Cycle    -   9 Minutes Remaining: 2 Audible Notification Cycle    -   6 Minutes Remaining: 3 Audible Notification Cycle    -   3 Minutes Remaining: Audible Notification Cycle Repeats until        the Battery is Fully Discharged

For example, when a low-battery condition is detected, the followingnotification sequences can occur. A tone sequence can be played whenthere is about 15 minutes of power remaining to indicate that there areabout 15 minutes (+/− about 1 minute) remaining of power. A tonesequence can then be played one time at about 12 minutes of powerremaining to indicate that there are about 12 minutes (+/− about 1minute) remaining of power. At about 9 minutes of power remaining, atone sequence can be played for a first time with a time intervalfollowed by the tone sequence being played a second time to indicatethat there are about 9 minutes (+/− about 1 minute) remaining of power.At about 6 minutes of power remaining, a tone sequence can then beplayed for a first time followed by a time interval followed by the tonesequence being played a second time that is then followed by anothertime interval and the tone sequence being played a third time toindicate that there are about 6 minutes (+/− about 1 minute) remainingof power. With about 3 minutes of power remaining, tone sequences can berepeated with time intervals in between the tones to indicate that thebattery is about to die until the power is off and/or the battery diesor is recharged or replaced.

Headlight device 10 as described herein can utilize an LED light sourcewith an active cooling system. A thermostatically-controlled cooling fancan draw air at a very low flow rate through vents on the side and backof the luminaire, quietly cooling the LED. The air can be drawn througha system of vents and tubes, or ducts, and can be gently exhaustedbehind the surgeon. The headlight device can be designed to provideillumination to aid visualization during minor surgical, diagnostic, ortherapeutic procedures. For example, as mentioned above, the headlightdevice can be used in neonate trans-illumination, ophthalmic procedures,or with photosensitive patients who have received photosensitizingagents (hematoporphyrin derivatives) within three months prior to theoperation.

Embodiments of the present disclosure shown in the drawings anddescribed above are exemplary of numerous embodiments that can be madewithin the scope of the appending claims. It is contemplated that thedevices and related methods can comprise numerous configurations otherthan those specifically disclosed.

What is claimed is:
 1. A headlight device comprising: a luminairecomprising a housing, the housing comprising a luminaire vent forreceiving cooling air and a light source contained within the housing;an air moving device outside of the luminaire, the air moving devicebeing for facilitating an intake of cooling air through the luminairevent; and an exhaust tube in communication with the luminaire and withthe air moving device to allow the cooling air to flow between theluminaire and the air moving device.
 2. The headlight device accordingto claim 1, further comprising a controller in communication with theluminaire and the air moving device.
 3. The headlight device accordingto claim 2, wherein the controller comprises a controller housing, inwhich a controller board and the air moving device reside.
 4. Theheadlight device according to claim 3, wherein the controller housingfurther comprises an air flow tube, which is connected to the exhausttube and is configured to direct an air flow from the exhaust tube tothe air moving device.
 5. The headlight device according to claim 2,wherein the controller is adapted to automatically control a temperatureof the light source.
 6. The headlight device according to claim 5,wherein the controller is adapted to automatically control a speed ofthe air moving device and an intensity of a light generated by the lightsource to control the temperature of the light source.
 7. The headlightdevice according to claim 1, wherein the light source comprises at leastone light emitting diode (LED).
 8. The headlight device of claim 7,wherein the luminaire further comprises: a circuit board with an openingtherethrough, the LED being electrically connected to the circuit board;a thermal conductive board having a protrusion extending through theopening to thermally contact the LED; and a heat sink thermally coupledto the thermal conductive board.
 9. The headlight device of claim 7,wherein the luminaire further comprises an optical assembly comprising:a condensing lens; an objective lens; an iris control placed between thecondensing lens and the objective lens; and a folding mirror disposedbetween the condensing lens and the objective lens.
 10. The headlightdevice of claim 9, wherein the condensing lens is disposed in closeproximity to the LED and is shaped as a meniscus lens.
 11. The headlightdevice of claim 7, wherein the luminaire further comprises an opticalassembly comprising: a first condensing lens and a second condensinglens; a first objective lens and a second objective lens; an iriscontrol disposed between the condensing lenses and the objective lenses;and a folding mirror disposed between the first objective lens and thesecond objective lens.
 12. The headlight device according to claim 1,wherein the air moving device comprises a fan.
 13. The headlight deviceaccording to claim 1, wherein the exhaust tube comprises a head wearableportion to which the luminaire is attached.
 14. The headlight deviceaccording to claim 1, further comprising a head wearable portion towhich the luminaire and the exhaust tube are attached.
 15. The headlightdevice according to claim 14, wherein the air moving device is at a rearof the head wearable portion and the exhaust tube extends around a sideof the head wearable portion.
 16. The headlight device according toclaim 1, further comprising a battery pack operable to alert a user whenthe battery pack is low on power.
 17. A method of operating a headlightdevice, the method comprising: providing a headlight device comprising:a luminaire comprising a housing, the housing comprising a luminairevent for receiving cooling air and a light source contained within thehousing; an air moving device outside of the luminaire, the air movingdevice being for facilitating an intake of cooling air through theluminaire vent; and an exhaust tube in communication with the luminaireand with the air moving device to allow the cooling air to flow betweenthe luminaire and the air moving device; and controlling a temperatureof the light source by using the air moving device to generate air flowthrough the luminaire vents, over the light source, through the exhausttube, and through the air moving device.
 18. The method according toclaim 17, wherein controlling the temperature of the light sourcefurther comprises setting the air moving device to a low speed.
 19. Themethod according to claim 17, wherein controlling the temperature of thelight source further comprises setting the air moving device at avariable speed ranging from a low speed to a high speed, the variablespeed being set at a value proportional to the temperature of the lightsource.
 20. The method according to claim 17, wherein controlling thetemperature of the light source further comprises setting the air movingdevice to a high speed.